Carton erector apparatus and process



E. C. SHERMAN CARTON ERECTOR APPARATUS AND PROCESS Sept. 26, 1967 6 Sheets-Sheet 1 Filed March 16, 1965 INVENTOR. EARL/5 C. SHERMAN ATTORNEY Sept. 26, 1967 E. c. SHERMAN CARTON ERECTOR APPARATUS AND PROCESS 6 Sheets-Sheet 2 Filed March 16, 1965 INVENTOR. EARL/5 c. SHERMAN BY Q 76d. Am

ATTORNEY v P 26, 1967 E. c. SHERMAN 3,343,466

CARTON ERECTOR APPARATUS AND PROCESS Filed March 16, 1965 6 Sheets-Sheet 5 r a) I l W M \Q vi w ,II" C g Q (3 j 9 (Q1 INVENTOR. EARLE C. SHERMAN BYKJM A T TORNE Y p 26, 9 E. c. SHERMAN 3,343,466

CARTON ERECTOR APPARATUS AND PROCESS Filed March 16, 1965 6 Sheets-Sheet 4 INVENTOR. EARLE C. SHERMAN BY Pam A T TORNE Y Sept. 26, 1967 E. c. SHERMAN CARTON ERECTOR APPARATUS AND PROCESS Filed March 16, 1965 ,6 Sheets-Sheet 5 I Illllllllllllllllll IIHIIT E @imd FIG 8 A 7: TORNEY United States Patent Ofiice 3,343,456 Patented Sept. 26, 1967 3,343,466 CARTON ERECTOR APPARATUS AND PROCESS Earle C. Sherman, Monroe, La., assignor, by mesne assignments, to Olinkraft, Inc., West Monroe, La., a corporation of Delaware Filed Mar. 16, 1965, Ser. No. 440,103 4 Claims. (Cl. 9353) The present invention relates to folding cartons such as basket-style, multiple-cell cartons and relates in particular to an apparatus and to a process for automatically and continuously erecting collapsed folding cartons.

The apparatus and process of the invention are most useful in the class of folding cartons which embrace a handle portion projecting above and supporting a depending multiple-cell body portion.

A particular feature of the invention is the provision of a novel apparatus operable to advance a collapsed carton along a generally straight-line path at uniform speed during the erection steps.

A further feature of the invention is the provision of a novel process for converting a collapsed carton into an erect carton.

A further feature of the invention is a process for continuously erecting folding cartons including the step of locking the cartons in the erect condition.

An apparatus embracing certain features of the present invention useful to erect and lock a carton having a bandle portion and a multiple-cell body portion may comprise means for engaging and feeding the handle portion of the carton at a uniform speed and along a generally straight-line path, opposed, reciprocating operating plate means efifective to engage and expand said body portion into a generally rectangular structure, stop means carried by said plate means operable to engage and block advance of said body portion and plunger means engageable with said body portion operable to actuate a carton lock, said plate means being timed relative to the operation of said plunger means effective to withdraw said stop means after the carton is locked.

A process embracing certain features of the present invention and useful to expand or to erect a basket-style multiple-cell article carrier from a collapsed to an erect condition may comprise the steps of continuously advancing a handle portion of the carton along a generally straight-line path at a uniform speed, restraining a leading edge of a body portion of said carton while continuing to advance said handle portion, said leading edge tending to move along a path generally normal to said straightline path until said handle portion overtakes said leading edge whereupon said carton is in erect condition, locking the carton in the erect condition and thereafter releasing said leading edge to permit the handle portion and the body portion of the carton to proceed in unison along said straight-line path at said uniform speed.

Other features and advantages of the present invention will become more apparent from an examination of the succeeding specification and claims when read in conjunction with the appended drawings, in which:

FIG. 1 is a perspective view of an erector apparatus whose operation utilizes the process steps of the present invention;

FIG. 2 is an elevational view of FIG. 1, somewhat enlarged, as observed from the discharge end;

FIG. 3 is a perspective view of FIG. 2 showing the operating plates straddling a collapsed carton;

FIG. 4 is a view similar to FIG. 3 showing a carton in the erect condition with the plunger means in position to lock the carton in the erect condition;

FIGS. 5, 6, and 7 show, schematically, the sequence of erection steps and the relative position of the stop means and plunger means during the erection sequence;

FIG. 8 is a plan View of the erector apparatus gear train including the plunger means structure;

FIG. 9 is a vertical section of FIG. 8 as viewed in the plane labeled 99; and

FIG. 10 is a perspective view of the erector apparatus as viewed from the supply end with the magazine for collapsed blanks removed.

As is apparent in FIG. 1, the erector apparatus, indicated generally by the reference numeral 10, comprises a main body structure S, supporting parallel shaft plates P, and carried by wheels W. The erector apparatus includes a magazine or hopper R filled with collapsed cartons C and is fitted with a tray along which erected cartons E are discharged.

Referring now in more detail to FIGS. 2, 3, 4, and 8 through 10, note that shaft plates 11 and 12 carry bearings for drive shafts 13, 14, 16, and 17, each keyed to and driving a mating gear 18, 19, 21, and 22.

Main drive gear 23, driven by roller chain 24 and sprocket 25, meshes with gear 19 to provide power for the erector device in a manner which will be described in detail later.

The roller chain 24 is powered by a conventional electric motor not shown.

Each shaft 13, 14, 16, and 17 is fitted with a mating crank identified by the reference numerals 26, 27, 28, and 29. Cranks 26 and 28 are pivotally connected to an operating plate 31 through pins 32 and 33 while cranks 27 and 29 make a corresponding connection with a complementary operating plate 34.

Each operating plate 31 and 34 in combination with its mating crank is counter-balanced to create a flywheel effect by counter weights 36 through 39.

Each operating plate 31 through 34 carries a plurality of suction or vacuum cups 41-41 operative to engage and make a temporary connection with a collapsed carton in a manner and for a purpose which will be described in greater detail hereinafter.

As stated previously, drive gear 23 meshes with and drives gear 19 in the direction shown. Gear 19 also meshes with and drives gear 18.

Gears 21 and 22 are driven by means of the link connectlion effected by the operating plates 31 and 34 respective y.

In order to maintain proper phasing and to keep plates 31 and 34 parallel, gears 21 and 22 run in meshing contact with one another.

Shaft plate 43 supports a pair of cooperating V-belt and sheave assemblies identified by the reference numerals 44 and 45, respectively.

Since both assemblies are identical in structure, the elements of assembly 44 will be described recognizing that the description also applies to assembly 45. Sheaves 46, 47, and 48, carried by shaft plate 43, are encircled by a V-belt 49.

The plate 43 also carries a plurality of intermediate pressure sheaves or pulleys 51-51 effective to maintain V-belt 49 in firm face-to-face contact with a cooperating V-belt 53 of assembly 45.

In some arrangements of the invention, it may be desirable to spring-load pressure pulleys 51-51 in order to insure firm contact between V-belts while permitting sufiicient separation or give when a handle portion 54 of a collapsed carton C enters and transverses the nip between the belts.

The power for the sheave assemblies 44 and 45 is provided by shaft 56 keyed to drive pulley 23.

Shaft 56 is formed with a flange 57 (FIG. 10) complementary to and spaced from a corresponding flange 58 carried by a shaft 59 supported in shaft plate 43. The drive 3 connection between flanges 57 and 58 for transferring power from shaft 56 to shaft 59 is effected by crank bolt 61.

As will be describedin more detail hereinafter, bolt 61 is eccentrically mounted relative to plates 57 and 578 while shafts 56 and 59 are concentric to these plates with the result that rotation of shaft 56 by drive gear 53 is effective to actuate a feed plate 62 through feed crank link 63 (see FIGS. 2 and in a fashion which will be described in greater detail as the specification proceeds.

Shaft 59 extends through shaft plate 43 and by means of suitable sprockets and a roller chain (not shown) makes a driving connection with sheaves 47.47 of each assembly.

Referring now, in particular, to FIGS. 8, 9, and 10, the the structure of the carton lock device will be described.

Note that shaft 14 carries a cam 60 formed with a cam face 66 mounted immediately adjacent and rotating with gear 19. Cooperating with the cam face 66 is a follower 67 carried .by (fixed to) a link 68 pivotally mounted at one end by means of pin 69 to movable rod 71.

The opposite end of link 68 makes a driving connection with reciprocating plunger means 72 formed with a roller 73. a 7 As cam 66' rotates along with gear 19 and in timed relationship with respect to the advance of a carton blank C, plunger means 72 moves from the rest position shown in FIG. 3 to the operated position shown in FIG. 4 to cause roller 73 to engage a portion of the bottom of carton C effective to actuate the carton lock.

Since the link 68 fulcrums about follower 67, coil spring 70 acts to hold the follower in contact with the cam face 66 and also serves to retract plunger means 72.

The carton blanks C are fed from the magazine R by a conventional feed plate 62 having blank engaging dogs 74 and 76 at the rear and formed with guide rods or rails 77 and 78 at the forward end.

7 Guide rods 77 and 78 are received in mating tracks 79 and 81 so that the rods 77 and 78 are free to move to and fro along the tracks as feed plate 62 is oscillated back and forth, beneath the magazine, by connecting rod 63 secured to the underside of the feed plate as at 82.

Rotation of flanges 57 and 58 carrying eccentrically disposed crank bolt 61 operates to reciprocate feeder plate 62 back and forth beneath the magazine R effective to permit dogs 74 and 76 to deal a collapsed blank C from the bottom of the magazine and advance it toward the nip of V-belt assemblies 44 and 45 in continuous fash- Any conventional blank feeding means may be utilized so long as the timing of the blank feeding is susceptible of synchronization with the advance of the blank, actuation of the operating plates 31 and 34, and the thrust of the plunger means.

Operation Upon applying power to the drive gear 23, and assuming that the feed plate 62 and its connecting rod 63 are in the position shown in FIG. 2, rotation of shafts 56 and 59 (see FIGS. 2 and 10) operates to start feeder plate 62 forward (toward discharge end) to advance handle portion 54 of blank C into the nip generated by V'-belts 49 and 53. At this time, V-velts 49 and 53 impart a uniform velocity to blank C.

V The body portion 83 of blank Cpasses between operat ing plates 31 and 34 clear of their cooperating suction cups 4141.

As the collapsed blank C, pinched between V-belts 49 and 53, proceeds along a generally straight path at uniform speed, the timing of main gear 23 and cooperating drive gears 18, 19, 21, and 22 is such that plates 31 and 34 are cranked together to the position shown in FIG. 3. Vacuum or suction cups 41-41 on opposed sides of the body portion 83 of the blank C engage and make a driving connection with the carton.

If desirable, a vacuum (or a pressure) can be applied at appropriately timed intervals to the cups 4141 to aid in making and breaking the driving connection with the carton C. Conduit is provided for this purpose.

As is apparent in FIG. 3, stop means defining a U- shaped fork 84 and a cooperating dog 86 are in position to block advance of the leading edge 87-87 of the body portion 83 of the blank C while the handle portion 54 I continues to advance at said uniform speed.

Next, the elements of FIG. 3 assume the position shown in FIG. 4 wherein the leading edges 8787 of the body portion 83 have moved upwardly along a path generally normal to the line of advance of the handle :portion 54. This occurs because the vacuum cups 4141 carried by operating plates 31 through 34 separate the side walls to erect the body portion of the carton.

Just prior to the withdrawal of the stop means (fork 84 and dog 86) the high of cam 66 is presented to its follower 67 effective through link 68 to drive plunger means 72 and its accompanying roller 73 toward the carton bottom 88 driving the bottom into locking relationship with hook 89.

In FIGS. 5, 6, and 7, the sequence of erection steps are shown schematically.

The handle portion 54 of blank C is advanced in the direction shown until the leading edges or corners 87--87 of body portion 83 of blank C encounter fork 84 and dog 86 of the stop means.

Since the edges 8787 are disposed in advance of the corresponding edge 91 of handle portion 54, it is possible to continue motion of the handle portion at a uniform speed even though forward motion of edges 8787 is arrested by the stop means.

As a result of continued forward travel of handle panel 54 and the separating force created by suction cups 41.41, leading edges 8787 move upwardly and downwardly, respectively (see FIG. 6), along a path generally normal to the over-all direction of advance by handle portion 54.

FIG. 7 shows the handle portion 54 having overtraveled leading edges 87--87 slightly (before release of edges 8787 revealing carton lock means defining hook 89 and notch 90. Just prior to the withdrawal of operating plates 31 and 34 and their accompanying stop means and suction cups, cam 66 is operative to drive plunger means 72 inwardly to set notch 90 in position to engage hook 89 in well-known fashion.

The timing of the stop means and the plunger means is such that the stop means withdraws (and connection with suction cups is broken) an instant prior to the withdrawal of the plunger means taking advantage of the natural resilience of the carton (its tendency to collapse) to set the lock. Thereafter, belts 49 anad 53 continue to advance the locked carton C until deposited on the discharge tray T.

Carton advance is maintained by utilizing one erect carton to drive the preceding carton.

It is anticipated that a wide variety of modifications and changes will be devised in the present invention without departing from the spirit and scope thereof.

What is claimed is:

1. An apparatus for erecting a collapsed folding carton and for locking the carton in an erect position, said carton including a handle portion, a multi-cell body portion, and a carton lock comprising means for engaging and feeding the handle portion at a uniform speed, opposed reciprocating vacuum plates operable to engage and expand said body portion into a generally rectangular structure, stop means carried by said plates operable to engage and block advance of said body portion while said handle portion is being advanced at said uniform speed and plunger means engageable with said body portion operable to actuate said carton lock, said plates being timed relative to the operation of said plunger means effective to withdraw said stop means after said carton is locked.

2. The apparatus of claim 1 wherein the means for engaging and feeding the handle portion including a pair of cooperating endless V-belts, said V -belts being in contact with one another over an appreciable area elfective to provide an elongated nip.

3. In a folding carton of the type having a combined handle portion and a multi-cell body portion, said handle portion projecting beyond the margin of the body, a method of expanding the carton from a collapsed condition to an erect condition comprising the steps of advancing the handle portion longitudinally along a generally straight-line path at a uniform speed, holding a leading edge of said body portion while continuing to advance said handle portion and simultaneously moving said leading edge along a path generally normal to said 15 straight-line path until said handle portion overtakes said leading edge and thereafter releasing said leading edge effective to permit the handle portion and body portion to proceed along with said straight-line patch at said uniform speed.

4. The process of claim 3 wherein the carton is locked in the erect condition before releasing said leading edge.

References Qited UNITED STATES PATENTS 2,780,970 2/1957 Gentry 93--53 3,027,815 3/1962 Anness et al. 93-53 BERNARD STICKNEY, Primary Examiner. 

1. AN APPARATUS FOR ERECTING A COLLAPSED FOLDING CARTON AND FOR LOCKING THE CARTON IN AN ERECT POSITION, SAID CARTON INCLUDING A HANDLE PORTION, A MULTI-CELL BODY PORTION, AND A CARTON LOCK COMPRISING MEANS FOR ENGAGING AND FEEDING THE HANDLE PORTION AT A UNIFORM SPEED, OPPOSED RECIPROCATING VACUUM PLATES OPERABLE TO ENGAGE AND EXPAND SAID BODY PORTION INTO A GENERALLY RECTANGULAR STRUCTURE, STOP MEANS CARRIED BY SAID PLATES OPERABLE TO ENGAGE AND BLOCK ADVANCE OF SAID BODY PORTION WHILE SAID HANDLE PORTION IS BEING ADVANCED AT SAID UNIFORM SPEED AND PLUNGER MEANS ENGAGEABLE WITH SAID BODY PORTION OPERABLE TO ACTUATE SAID CARTON LOCK, SAID PLATES BEING TIMED RELATIVE TO THE OPERATION OF SAID PLUNGER MEANS EFFECTIVE TO WITHDRAW SAID STOP MEANS AFTER SAID CARTON IS LOCKED. 